Apparatus and method for packaging flanged reels

ABSTRACT

An apparatus and method for packaging stacks of reels of the type having a hub with an axial bore therethrough and circular flanges secured to the hub ends. In one embodiment, the fixture has a plurality of slidably mounted bars having stepped reel supporting surfaces of varying height. In another embodiment, the apparatus has a rectangular or square reel supporting fixture in which the reel supporting surface is provided with recesses and raised portions between the recesses. Each recess, raised portion or stepped surface has a guide opening to facilitate the loading of a plurality of rows of stacked reels on the fixture with the reel flanges in adjacent stacks arranged in interleaved or nested relation due to the difference in elevation or distance between adjacent reel supporting surfaces. The method of packaging the reels comprises placing a stack of reels on a guide rod, loading the stacks of reels and guide rods, preferably one stack at a time, on the fixture in interleaved relation, placing an inverted box over a full load of the stacks of reels, removing the guide rods from the stacks of reels, and inverting the fixture and box loaded with reels.

United States Patent 1 1 Crow, Jr. et al.

[ 1 Jan. 30, 1973 [54] APPARATUS AND METHOD FOR PACKAGING FLANGED REELS[73] Assignee: Eastman Kodak cit, Rochester,

[22] Filed: March 10,1971

21 Appl.No.: 122,950

[52] US. Cl. ..53/26, 53/390, 206/52 F, 269/40 [51] Int. Cl. ..B65b35/30 [58] Field of Search ..53/26,159, 161, 390, 392; 206152 F, 65 R;269/40, 45, 50

[56] References Cited UNITED STATES PATENTS 2,054,514 9/1936 Landes..53/26 2,710,151 6/1955 Delaney ..206/65 R X 2,738,979 3/1956 Dalton..206/65 R X 1,622,493 3/1927 Craig ..53/392 X FOREIGN PATENTS ORAPPLlCATIONS 220,847 4/1962 Austria ..206/52 F Primary ExaminerGranvilleY. Custer, Jr. Assistant ExaminerEugene F. Desmond Att0rneyWilliam T.French, Robert F. Crocker and I Steve W. Gremban [57] ABSTRACT Anapparatus and method for packaging stacks of reels of the type having ahub with an axial bore therethrough and circular flanges secured to thehub ends. In one embodiment, the fixture has a plurality of slidablymounted bars having stepped reel supporting surfaces of varying height.In another embodiment, the apparatus has a rectangular or square reelsupporting fixture in which the reel supporting surface is provided withrecesses and raised portions between the recesses. Each recess, raisedportion or stepped surface has a guide opening to facilitate the loadingof a plurality of rows of stacked reels on the fixture with the reelflanges in adjacent stacks arranged in interleaved or nested relationdue to the difference in elevation or distance between adjacent reelsupporting surfaces. The method of packaging the reels comprises placinga stack of reels on a guide rod, loading the stacks of reels and guiderods, preferably one stack at a time, on the fixture in interleavedrelation, placing an inverted box over a full load of the stacks ofreels, removing the guide rods from the stacks of reels, and invertingthe fixture and box loaded with reels.

13 Claims, 9 Drawing Figures PATENTED JAN 30 I975 SHEET 1 BF 5 i v A weQR R u m v R R n v R A I U; W Z Z Z k fi w w and: n J v n m w. 0,0. m H P..H .H L H .H..

ADRIAN 6'. RUN/0M5 RUFUS C. CROW JR.

2v INVENTORS ATTORNEY PATENTED JAN 30 I973 sum 2 BF 5 ADR/A/V 6. RUN/0N5RUFUS C. CROW JR INVENTORS 4r ram/Er PATENTEDJANSO I973 3.713.266

SHEEI 3 UF 5 ADE/AN C. RUN/0N5 RUFUS C. CROW JR INVENTORS A T TOR/VE YPATENTED JAN 30 I975 SHEET 5 UF 5 ADR/A/V C. RUN/0N5 RUFUS 6. CROW JR.

INVENTORS.

BY%QM ATTORNEY APPARATUS AND METHOD FOR PACKAGING FLANGED REELSBACKGROUND OF THE INVENTION 1. Field of the Invention This inventionrelates generally to packaging, and more specifically to an apparatusand method for packaging stacks of flanged reels with the flanges ininterleaved relation.

2. Description of the Prior Art Reels have heretofore been packaged byplacing an open receiving box preferably in a partially inclinedposition, placing stacks of the reels with the flanges of the reelsinterleaved in side-by-side relation along the bottom of the box untilthe bottom row has been filled, placing a flat spacer board over thebottom row of stacked reels, and repeating the operation until the boxis filled with reels. This prior known method of packaging reels,although satisfactory, presents several problems and disadvantages.Since the flanges of the reels are interleaved from side to side only, alarge amount of air space exists between the spacer board and the reelhub and flange peripheries, resulting in a box of reels that is not toocompact or firm, and one in which the quantity of reels is relativelysmall. Applicants improved apparatus and method for packaging reels incompletely interleaved relation results in greatly increasing thequantity of reels that may be placed in a similar sized package or box,prevents accumulation of dust on reels which results from movementwithin the package in transit, and results in a box that is much morefirm or rigid and resistant to damage during handling and in transit. Inaddition, such interleaving reduces the packaging material costs by asmuch as 50 to 75 percent, reduces labor costs appreciably, reduces thenet shipping weight, reduces the storage space for an equivalentquantity of reels by as much as 30 percent, and has an ecologicaladvantage in reducing waste disposal.

SUMMARY OF THE INVENTION This invention includes within its scope animproved method and apparatus for packaging reels of the type having ahub with an axial bore therethrough, and circular flanges secured to theends thereof. The apparatus generally comprises a fixture lying in oneplane and having two or more reel supporting surfaces parallel to theplane and displaced different distances therefrom. More specifically,the apparatus in one embodiment comprises a fixture for slidablysupporting a plurality of bars having reel supporting stepped surfacesof varying height. In another embodiment, the apparatus comprises asubstantially rectangular or square fixture having a plurality ofcircular or partially circular reel supporting recesses in one surfaceof the fixture of the same radius as the reel flanges, and adjacentraised or elevated reel supporting portions between the recesses. Thereel supporting recesses, raised portions or stepped surfaces have guideopenings therethrough which have one end blocked by a slide plate in itsclosed position, and which are open at the other end to receive the endsof guide rods onto which is mounted a stack of reels in alignment withone another. By virtue of the arrangement of the recesses, raisedportions and stepped surfaces, and the distance between the reel hubs,the flanges of the adjacent rows or stacks of reels I are interleaved.This results in a full load of stacked reels that is firmer, more rigid,and more compact than heretofore possible. When the load of stackedreels is complete, an inverted plastic bag and box is placed over theload of reels, the sliding plate in the fixture is withdrawn to its openposition permitting removal of the guide rods which fall via gravityfrom the stacks of reels and into a receiving bin underneath thefixture, and the fixture and box are inverted. The fixture may then beremoved or returned to its original position, and the box closed andsealed for shipment.

One of the objects of the present invention is to provide an apparatusand method for packaging flanged reels that substantially reducespackaging material costs, labor costs, net shipping weight, storagespace, and waste disposal over prior known apparatus and methods.

Another object of the invention is to provide an improved apparatus andmethod for packaging flanged reels that results in a more compact, firm,and rigid box of reels, thereby substantially reducing the possibilityBRIEF DESCRIPTION OF THE DRAWING In the detailed description of thepreferred embodiments presented below, reference is made to theaccompanying drawings, in which:

FIG. 1 is a top plan view of one embodiment of a reel supporting fixturefor practicing the method of this invention;

FIG. 2 is a side elevational-view of the reel supporting fixture of FIG.1;

FIG. 3 is an enlarged perspective view of a portion of the fixture ofFIG. 1 showing reels mounted thereon in interleaved relation;

FIG. 4 is a top plan view of another embodiment of the fixture of thisinvention;

FIG. 5 is a side elevational view of the fixture of FIG. 4 mounted on atable and showing some reels mounted on the fixture in interleavedrelation;

FIG. 6 is a top plan view of a full load of interleaved reels;

FIG. 7 is a side elevational view showing a plastic bag and box ininverted position placed over the load of reels;

FIG. 8 is a top plan view showing the fixture and loaded box invertedthrough substantially for placing the box in an upright position, andfurther showing the slide plate for removing the guide rods; and

FIG. 9 is a top plan view showing the box in a position to be closed,and the fixture returned to its normal position for receiving anotherload of reels.

DESCRIPTION OF THE PREFERRED EMBODIMENTS With reference to the drawings,a method and apparatus are shown for packaging flanged reels 8 (seeFIGS. 3 and of the type having a hub 10 with an axial bore 12therethrough, and circular flanges 14 secured to the ends of the hub 10.In the apparatus, a table 16 is provided for supporting a substantiallyrectangular or square (depending upon the shape of box to be used) reelsupporting fixture 18 that is preferably hinged to table 16 along oneedge by any suitable hinge 20 as best seen in FIGS. 5 and 8. In theembodiment of the fixture shown in FIGS. 1-3, a frame 22 is providedhaving a pair of parallel, spaced apart guide rails 24 having their endssecured by any suitable means to opposite sides of the frame. Aplurality of bars 26 are slidably mounted on guide rails 24, and eachbar is provided with a plurality of stepped, flat, reel supportingsurfaces 28 to facilitate interleaving of adjacent reels 8 on bar 26.Each of the surfaces 28 is provided with an opening 30 extending throughthe bar for receiving a guide rod 32, and the openings 30 are spacedapart a distance substantially equal to the radius of a flange 14 plusthe radius of a hub 10 so that adjacent reels 8, when interleaved, havethe hub 10 of one abutting the flange 14 of the other. To facilitatemounting a rod 32 and stack of reels 8 on each surface, a substantiallyV-shaped groove 34 is provided on each surface leading to opening 30 asbest seen in FIGS. 1 and 3. In order to provide interleaving of reels 8on adjacent bars 26, the bars designated A, C and E in FIG. 2 areidentical and have their surfaces 28 displaced predetermined distancesfrom a reference plane passing through the bottom surface 36 (see FIGS.2 and 3) of the bars. The bars designated B and D in FIG. 2 havesurfaces 28 identical to corresponding surfaces 28 on bars A, C and E,and openings 30 spaced apart the same distance. However, thecorresponding surfaces 28 on bars B and D are displaced or elevated agreater distance from surface 36 than the corresponding surfaces 28 onbars A, C and E by an amount at least twice the thickness of a flange 14to facilitate interleaving of corresponding reels 8 on adjacent bars 26when the bars are moved together. To provide a full load of reels 8,preferably bar A is loaded with stacks of reels starting from thehighest center surface 28 and moving toward the ends of the bar. Theloaded bar A is moved to one end of the guide rails 24. Then bar B isloaded in a similar fashion and when loaded is slid into engagement withbar A with the reel flanges 14 in interleaved relation. The sameprocedure is followed for the remaining bars C, D and E until the reelload is completed. The method of packaging a full or complete load ofreels 8 will be described hereinafter.

In the embodiment of the fixture 18' shown in FIGS. 4-6, the fixture isprovided with a plurality of circular and partially circular recesses 38of a radius slightly larger than the radius of flange l4, and raised orelevated portions 40 therebetween. The vertical or elevated distancebetween the reel supporting surfaces of the recesses 38 and the reelsupporting surfaces of the raised portions 40 is at least as great astwice the thickness of a flange 14 to facilitate interleaving ofadjacent flanges. Each of the recesses 38 and raised portions 40 isprovided with an opening 42 extending completely through fixture l8, andthe openings 42 are spaced apart a distance at least equal to the radiusof a flange 14 plus the radius ofa hub 10 so that the hub 10 and flange14 of adjacent interleaved reels 8 are in abutting relation. To loadfixture 18', the operator initially places reels 8 on a rod 32 to form astack of reels, and preferably starting from the center of fixture 18'and working out towards the periphery places the stacks of reels 8, oneat a time, on the fixture with one of the ends of rod 32 inserted in anopening 42 in a recess 38 or raised portion 40. By virtue of thevertical distance or elevation between the horizontal surfacesof therecesses 38 and raised portions 40, and the distance between adjacentopenings 42, which is less than the diameter of a reel 8, and preferablyat least equal to the sum of the radius of a reel flange l4 and theradius of a hub 10, the adjacent stacks of reels 8 are mounted ininterleaved or nesting relation.

With regard to loading the fixtures 18, 18' with reels and packagingeach load, table 16 is provided with guideways 44 as best seen in FIG. 8for slidably supporting a thin, flat, rectangular slide plate 46 whichin its fully closed position, as seen in FIG. 1, blocks off the lowerends of the openings 30, 42 in the fixtures 18, 18' respectively. Toform a load of nested stacks of flanged reels 8, the operator places astack of reels 8 of the correct number and length on rod 32, preferablyby inserting the rod through the bores 12 of a stack of reels 8, andthen loads the rod with the stacked reels on fixture 18. When thefixture is fully loaded, an inverted plastic bag 48 and box 50,preferably a corrugated cardboard box, is placed over the load of reels8 as seen in FIG. 7. Following this, the slide plate 46 is moved to anopen position for removing the rods which fall via gravity into areceiving bin 52 of any suitable type at the base of table 16. The box50 and fixture 18, 18' are then pivoted as a unit through an angle ofsubstantially about hinge 20 to the position seen in FIG. 8, reinvertingthe box so that it is now in its normal upright position and resting ona platform 54. The fixture 18, 18' may be returned to its normalposition as seen in FIG. 9, and the bag 48 and box 50 may be closed andsealed for shipment. The slide plate 46 is returned to its normal closedposition, and the fixture 18, 18' is once again in position to receive aload of nested reels 8 as seen in FIG. 1.

The invention has been described in detail with particular reference topreferred embodiments thereof, but it will be understood that variationsand modifications can be effected within the spirit and scope of theinvention as described hereinabove. I

We claim:

1. In an apparatus for use in packaging stacks of positioned relative toone another that flanges of the reels in each stack will interleave withthe flanges of an adjacent stack.

2. In an apparatus for use in packaging flanged reels in interleavedrelation, the combination comprising:

a fixture having a plurality of reel supporting recesses substantiallyin abutting relation and large enough to receive a flange of a reel, andreel supporting elevated portions between said recesses in which thevertical distance between the reel-supporting surfaces of said recessesand elevated portions is at least twice as great as the thickness of aflange; and

means comprising openings in said recesses and said elevated portionsfor releasably holding stacks of reels in predetermined positionsthereon, said recesses, said elevated portions and said holding meansbeing so positioned relative to one another that flanges of the reels ineach stack will interleave with the flanges of an adjacent stack.

3. The invention according to claim 2 wherein said recesses arecircular, and said openings are centrally positioned in said recessesand elevated portions and spaced apart a distance at least equal to theradius of a flange plus the radius of a reel hub.

4. The invention according to claim 2 wherein said apparatus furthercomprises a support, and said fixture is hingedly mounted on saidsupport.

5. The invention according to claim 2 wherein said apparatus furthercomprises a support for-said fixture, and said openings in said recessesand elevated portions extend through said fixture, rods for receivingreel hubs and each having one end extending into one of said openings,and blocking means are positioned below said openings and movablebetween closed and open positions for blocking and unblocking saidopenings respectively.

6. The invention according to claim 5 wherein said blocking meanscomprises a slidable plate.

7. The invention according to claim 5 wherein said blocking meanscomprises guideways on said support below said fixture, and a plateslidably movable on said guideways between said open and closedpositions.

8. In an apparatus for use in packaging in interleaved relation reels ofthe type having a hub and flanges secured to the hub, the combinationcomprising:

a fixture having guide means, a plurality of bars slidably supported bysaid guide means, each of said bars having stepped reel supportingsurfaces which are displaced different vertical distances from areference horizontal plane passing through the bottom of said bars, thevertical distances said reel supporting surfaces are displaced for oneof said bars being different than the vertical distances thecorresponding reel supporting surfaces are displaced for an adjacent barby a distance at least twice as great as the thickness of a flange; and

means associated with said reel supporting surfaces for releasablyholding a stack of reels in predetermined positions thereon, saidsurfaces and said holding means being 80 positioned relative to oneanother that the flanges of the reels in each stack will interleave withthe flanges of an adjacent stack.

9. The invention according to claim 8 wherein said holding meanscomprises openings in said reel supporting surfaces spaced apart adistance at least equal to the radius of a flange plus the radius of areel hub.

10. The invention according to claim 8 wherein said holding meanscomprises openings in said reel supporting surfaces spaced apart adistance at least equal to the radius of a flange plus the radius of areel hub, and rods for receiving reel hubs and each rod having one endextending into one of said openings.

11. A method for packaging in interleaved relation reels of the typehaving a hub with an axial bore and circular flanges secured to the endsof the hub, comprising the steps of:

forming a plurality of stacks of reels by placing a stack of reels oneach of a plurality of guide members for holding the individual stacksof reels in alignment; loading said plurality of stacks of reels on afixture having a plurality of reel supporting surfaces displaceddifferent distances from a reference plane with the flanges of adjacentstacks in interleaved relation; 1

placing a box having an open end over a full load of the stacks of reelson the fixture;

removing the guide members from the stacks of reels; and

inverting the box and fixture so that the open end of the box is now ontop and in position to be closed and sealed.

12. A method for packaging in interleaved relation reels of the typehaving a hub with an axial bore and circular flanges secured to the endsof the hub, comprising the steps of:

forming a plurality of stacks of reels by placing a stack of reels oneach of a plurality of rods in which the rod extends through the boresin said hubs;

loading said plurality of stacks of reels, preferably one stack at atime, on a fixture having a plurality of recesses and elevated portionsbetween the recesses for receiving the stacks of reels with the flangesof adjacent stacks in interleaved relation, the rods being insertable inopenings in the recesses and elevated portions;

placing a box having an open end over a full load of the stacks of reelson the fixture;

removing the rods from the stacks of reels; and

inverting the box and fixture so that the open end of the box is now ontop and in position to be closed and sealed.

13. A method for packaging in interleaved relation reels of the typehaving a hub with an axial bore and circular flanges secured to the endsof the hub, com-,

prising the steps of:

forming a plurality of stacks of reels by placing .a stack of reels oneach of a plurality of rods in which the rod extends through the boresin said hubs;

placing a plurality of the rods and stacks of reels on a fixture havinga plurality of bars with stepped reel supporting surfaces for receivingthe stacks of reels with the flanges of adjacent stacks in interleavedrelation;

placing a box having an open end over a full load of the stacks of reelson the fixture;

removing the rods from the stacks of reels; and

inverting the box and fixture so that the open end of the box is now ontop and in position to be closed and sealed.

1. In an apparatus for use in packaging stacks of flanged reels ininterleaved relation with a plurality of reels in each stack, thecombination comprising: a fixture having a plurality of adjacent reelsupporting surfaces displaced different distances from a commonreference plane; and means comprising an opening in each of said reelsupporting surfaces for slidably receiving a rod onto which a stack ofreels has previously been mounted for releasably holding said stack ofreels in a predetermined position thereon, said reel supporting surfacesand said holding means being so positioned relative to one another thatflanges of the reels in each stack will interleave with the flanges ofan adjacent stack.
 1. In an apparatus for use in packaging stacks offlanged reels in interleaved relation with a plurality of reels in eachstack, the combination comprising: a fixture having a plurality ofadjacent reel supporting surfaces displaced different distances from acommon reference plane; and means comprising an opening in each of saidreel supporting surfaces for slidably receiving a rod onto which a stackof reels has previously been mounted for releasably holding said stackof reels in a predetermined position thereon, said reel supportingsurfaces and said holding means being so positioned relative to oneanother that flanges of the reels in each stack will interleave with theflanges of an adjacent stack.
 2. In an apparatus for use in packagingflanged reels in interleaved relation, the combination comprising: afixture having a plurality of reel supporting recesses substantially inabutting relation and large enough to receive a flange of a reel, andreel supporting elevated portions between said recesses in which thevertical distance between the reel-supporting surfaces of said recessesand elevated portions is at least twice as great as the thickness of aflange; and means comprising openings in said recesses and said elevatedportions for releasably holding stacks of reels in predeterminedpositions thereon, said recesses, said elevated portions and saidholding means being so positioned relative to one another that flangesof the reels in each stack will interleave with the flanges of anadjacent stack.
 3. The invention according to claim 2 wherein saidrecesses are circular, and said openings Are centrally positioned insaid recesses and elevated portions and spaced apart a distance at leastequal to the radius of a flange plus the radius of a reel hub.
 4. Theinvention according to claim 2 wherein said apparatus further comprisesa support, and said fixture is hingedly mounted on said support.
 5. Theinvention according to claim 2 wherein said apparatus further comprisesa support for said fixture, and said openings in said recesses andelevated portions extend through said fixture, rods for receiving reelhubs and each having one end extending into one of said openings, andblocking means are positioned below said openings and movable betweenclosed and open positions for blocking and unblocking said openingsrespectively.
 6. The invention according to claim 5 wherein saidblocking means comprises a slidable plate.
 7. The invention according toclaim 5 wherein said blocking means comprises guideways on said supportbelow said fixture, and a plate slidably movable on said guidewaysbetween said open and closed positions.
 8. In an apparatus for use inpackaging in interleaved relation reels of the type having a hub andflanges secured to the hub, the combination comprising: a fixture havingguide means, a plurality of bars slidably supported by said guide means,each of said bars having stepped reel supporting surfaces which aredisplaced different vertical distances from a reference horizontal planepassing through the bottom of said bars, the vertical distances saidreel supporting surfaces are displaced for one of said bars beingdifferent than the vertical distances the corresponding reel supportingsurfaces are displaced for an adjacent bar by a distance at least twiceas great as the thickness of a flange; and means associated with saidreel supporting surfaces for releasably holding a stack of reels inpredetermined positions thereon, said surfaces and said holding meansbeing so positioned relative to one another that the flanges of thereels in each stack will interleave with the flanges of an adjacentstack.
 9. The invention according to claim 8 wherein said holding meanscomprises openings in said reel supporting surfaces spaced apart adistance at least equal to the radius of a flange plus the radius of areel hub.
 10. The invention according to claim 8 wherein said holdingmeans comprises openings in said reel supporting surfaces spaced apart adistance at least equal to the radius of a flange plus the radius of areel hub, and rods for receiving reel hubs and each rod having one endextending into one of said openings.
 11. A method for packaging ininterleaved relation reels of the type having a hub with an axial boreand circular flanges secured to the ends of the hub, comprising thesteps of: forming a plurality of stacks of reels by placing a stack ofreels on each of a plurality of guide members for holding the individualstacks of reels in alignment; loading said plurality of stacks of reelson a fixture having a plurality of reel supporting surfaces displaceddifferent distances from a reference plane with the flanges of adjacentstacks in interleaved relation; placing a box having an open end over afull load of the stacks of reels on the fixture; removing the guidemembers from the stacks of reels; and inverting the box and fixture sothat the open end of the box is now on top and in position to be closedand sealed.
 12. A method for packaging in interleaved relation reels ofthe type having a hub with an axial bore and circular flanges secured tothe ends of the hub, comprising the steps of: forming a plurality ofstacks of reels by placing a stack of reels on each of a plurality ofrods in which the rod extends through the bores in said hubs; loadingsaid plurality of stacks of reels, preferably one stack at a time, on afixture having a plurality of recesses and elevated portions between therecesses for receiving the stacks of reels with the flanges of adjacentstackS in interleaved relation, the rods being insertable in openings inthe recesses and elevated portions; placing a box having an open endover a full load of the stacks of reels on the fixture; removing therods from the stacks of reels; and inverting the box and fixture so thatthe open end of the box is now on top and in position to be closed andsealed.